p. 1 

## OAR Box 1147 Prepped by Ollie Stewart

Document

Number: 

## 215)IV-E-8 9 Docket Number: 

## A-87-1 1

Printed 4/22/2008 2:42:58 PM

Sheet 215of 242P.2

mT <* . 

## US B Xr* ^ ^ UNITE D STATE S ENVIRONMENTA L PROTECTIO N AGENC Y AN N ARBOR . MICHIGA N 4810 5 OFFIC E O F AI R AN D RADIATIO N MAR I 3 ^ MEMORANDU

M SUBJECT : FROM : TO : THRU : Battell e Industr yPrese n Pau l M . Laing , Chemica l Enginee r Standard s Developmen t an d Suppor t Branc h ^ Th e Recor d Glen n W . Passavant , Senio r Projec t Manag e Standard s Developmen t an d Suppor t Branc h r

### ^Ltdi^""-^
On Marc h 7 , 198 9 an EP Acontractor , Battelle , presente d the result s o f thei r tw o recentl ycomplete d draf t studies , "Fue l SystemComparativ e Ris k Assessment" , an d "Servic e Statio n Refueling Ris k Assessment " t o representative s fro mth e America n Petroleu

mInstitute , Moto r Vehicle s Manufacturer s Association , Automobil e Importer s o f America , an d individua l membe r companies . Acomplet e lis t o f attendee s i s attached . Als o attache d ar e a cop yo f the agend a an d Battelle' s briefin g charts . Attachment s cc : Docke t A-87-1 1 6903 W 

# JP. 3 Battell e IndustryPresentatio n Agend a Marc h 7 , 1989 ; 1:0 0 p.m . I . Openin g Remark s (EPA ) II . Fue l SystemComparativ e Ris k Assessmen t (Battelle ) III . Servic e Statio n Ris k Assessmen t (Battelle ) IV . Adjournmen t Battell e Team

Member s Davi d J . Mitchel l Jonatha n F . Luedek e Josep h A . Hoes s John T . Herridg e Michae l Murph

y
6891 WP. 4 

# w "Fue l SystemComparativ e Ris k Assessment " Battell e IndustryPresentatio n Marc h 7 , 1989 ; 1:0 0 p.m . Sign-I n Shee t *•( *

1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . 10 . 1 1 . 12 . 1 3 . 14 . 1 5 . 16 . 17 . 18 . 19 . 2 0 . 2 1 . 2 2 . 2 3 . 2 4 . 2 5 . Nam e
^ c - Company/Orqani za t io n A( A &mJ6tM 

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## P , l^uEb ^

- Shee t (Continued ) Company/Orqanizatio n 

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i Phon e 6o ; ia*?-a<?o 3r s 3>c3U^-0(

j* * 

## P Battel l e PRESENTATIO N o n SERVIC E STATIO N REFUELIN G RIS KASSESSMEN T

Marc h 198 9
Davi d J . Mitchel l (614)424-492 9 Raymon d E . Thompso n

(614)424-517 1 p C O

## Topic

s € * Battell e
1 ) Objective 2 ) Activitie s 3 ) Battell e Finding s 4 ) Impact o

fEP A Reductio n Factor s o n Battell e Finding s

r> i#fe l



## 1 ) Objectiv

e i l Battell e 3

Determin e risk

s associate d wit h curren t servic e statio n refuelin g event s

T J C O£f e



## Area s ofInteres t % $ Battell e Refuelin g Even t Consequences (numbe ro fincident s an d cost)

- Fire s
- Persona l injurie s
- Death s (numbe ro

fincidents only

)

- Fir e relate d propert

y damag e
- Non-fire relate d propert y damag e Hazard s

- Vapo remission s
- Liqui d spill s fro m vehicle s
- Liqui d spill s fro m nozzle s Geographica l Area

- Entir e U.S . excep

t State o fCaliforni a

T J CO

## 2 ) Activitie s OBaffell e Identif y th e dat a an d potentia l sources Obtai n an d revie

wavailabl e data Perfor m th e quantitativ

e ris k assessmen t

• • o

## Organization s Contacte d C l Battell e

America n Petroleu m Institute Automobil e Dealers-Servic e Departments Cente rfo rAut o Safet

y Cente rfo rFiresafet

y Studies/Worceste rPolytechni c Institute Dr y Cleaners Failur e Analysi s Associate s Federa l Highwa

y Administratio n Insurance Companie s Insurance Institute fo rHighwa y Safet y Majo rOi l Companie s Nationa l Cente rfo rStatistic s an d Analysis-DOT/NHTS A Nationa l Fir

e Protectio n Associatio n Nationa l Safet

y Counci l Nationa l Highwa

y Traffi c Safet

y Administratio n Ohi o Environmenta l Protectio n Agenc y Service Statio n Dealers o fAmeric a Societ y o fAutomotiv

e Engineers State Fir e Marshall s Transportatio n Researc h Board/Nationa l Academ y o fScience s United State s Consume rProduc t Safet y Commissio n United States Environmenta l Protectio n Agenc y United States Fire Administratio n

## Primar

y Dat a Source s € * Battell e

•NEIS S Data - U.S . Consume rProduct Safet y Commissio n
•NFIR S Data

- U.S . Fire Administratio n

- Cente rfo rFiresafety Studies , Worceste rPolytechni c Institut e

- U.S . Environmenta l Protectio n Agenc y

- Failure Analysi s Associate s Report

- Stat e o

fOhi o Fire Marshal' s Offic e •Non-fire Property Damag e Data - America n Petroleu m Institut e

r o

## 3 ) Battell e Findings : **Ranpii p

Incidents an d Cost s *#Banen e 8 Annua l Numbe ro

fRefuelin g Fire s 162/$198,00 0 Vapo rrelate d 4/$4,50 0

- Spil l relate d 158/$193,50 0 Annua l Numbe rofInjurie s 139 5

- Vapo rrelate d 3 9 Spil l relate d 135 6 Annua l Numbe rofDeath s 1 Annua l Numbe rofNon-Fire Relate d Refuelin g Incident s (property data ) N D

T l W

## 4 ) Impac t ofEPA Reductio n ^Battell e

Factor s o n Battell e Finding s Initia l Finding s

- 16 2 refuelin g relate d fire s annuall y 4 du e t o atomize d liquids/vapor s

- 15 8 du e t o spillag e EP A Assume d Reductio n Factors

- 100 % reductio n i n fire s du e t o atomize d liquids/vapor s 50 % reductio n i n fire s du e t o spillag e Projecte d Finding s 51 % o fal l refuelin g fire s woul d b e eliminate d

T l

## € * Battell e PRESENTATIO N o n FUE L SYSTE M COMPARATIV E RIS KASSESSMEN T

Marc h 198 9 Davi d J . Mitchel l (614)424-492 9 Jonatha n F . Luedek e (614)424-514 5

T l

## Topic s 1 ) Backgroun d

2 ) Objective/Scop e 3 ) Project Approac h 4 ) Overvie

wo fCase s Analyze d 5 ) Analysi s Approac h 6 ) Result s 7 ) Conclusion s 

## llBatteli e 2

j

*

## .m.

1 ) Backgroun d C l Battell e
Concer n expresse d b y severa l partie s ove r safety o fonboar d refuelin g emissio n contro l system s - increase d ris k o ffire EP A conducte d an d release d safety evaluatio n fo rpubli c commen t EP A publishe d NPR M Battell e retaine d t o perfor m independen t an d objective comparative ris k assessmen t (FMECA)

VA,\mrt-\-W T l

## 2 ) Objective/Scop e .$%. 

## O Battelle Objective

•Scop e Conduct comparativ e ris k assessmen t o

fspecifi c onboar d refuelin g emissio n contro l approache s versu s curren t approache s Limite d t o 1 0 fue l syste m configuration s define d b y EPA' s Offic e o

fMobil e Source s (An n Arbor , Michigan ) Hazard s are leakag e o

fliqui d fue l o rvapo r Thre e vehicl e operatin g state s addressed- - refueling , driving , parke d Gasolin e powered , passenge rcar s considere d (als o cover s ligh t truck s wit h simila rfue l syste m approaches )

T l o o

## 3 ) Projec

t Approac h O Battelle

Wor k Assignmen t Configuratio n Definitio n an d Confirmatio n FMEC A 

# I Draft Report J Safet y Grou p Review EP A Review Industry Revie w Publi c Commen t T Battell e Reanalysi s Fina l Report

T l CO< * %



## 4 ) Overvie

wo fCase s Analyze d M Battelle

Existin g Systems : Cas e 1 (Bas e Case ) Descripto r

Stoc k fue l injecte d (F.I. ) Majo rCharacteristic s 198 6 G M A bod y wit h por t fue l injectio n Stoc k carburete d 198 6 G M A bod y wit h carburetor , bow-ti e an d n o rollove rvalv

e

T l h o

## Overvie

wo fCase s Analyze d (Continued ) * % 

## O Battell e Modifie d System s - N o Onboar d Controls : Cas e Descripto r 2 Stoc k

F.I . wit h stee l fillpip e an d ventpip e 3 Stoc k

F.I . wit h enlarge d fillpip e 5 Stoc k

F.I . wit h submerge d fillpip e 6 Stoc k

carburete d wit h rollove rvalv

e Majo rCharacteristic s

Stoc k F.I . withou t flexibl e hos e i n fillpip e o rventpip e Stoc k F.I . wit h enlarge d fillpip e diameter , n o ventpip e Stoc k F.I . wit h extende d an d submerge d fillpip e i n fue l tan k Stoc k carburete d wit h rollove rvalve , n o bow-ti e

W/Arl-.l-m U h o

## Overvie

wo f (Continued ) Case s Analyzed 

# I I Battell e Modifie d System s - Wit h Onboard Controls : Cas e 8

1 0 Descripto r 7 Onboard wit h stee l fillnec k valv e Onboard wit h solenoi d tan k valv e Onboard wit h mechanica l tan k valv e Onboard wit h plasti c fillnec k valv e Majo rCharacteristic s

Stoc k F.I . wit h stee l fillnec k mounte d rollover/refuelin g ven t valv e an d liqui d sea l Stoc k F.I . wit h tan k

mounte d solenoi d rollover/refuelin g ven t valve , rea rcanister , liqui d sea l an d n o ventpip e Stoc k F.I . wit h tan k

mounte d rollover/refuelin g ven t valve , rea r canister , liqui d sea l an d n o ventpip e Stoc k F.I . wit h plasti c fillnec k mounte d rollover/refuelin g ven t valve , mechanica l sea l an d overfil l reliefvalv

e

KAA*M-+«I-I7 t

## Base Cas e Configuratio n

Stoc k Fue l Injecte d 

# I I Battell e

Fue l Injectio n Rai l Assembl y Fue l Fee dLin e Fue l Retur nLin e Loc kCam 

# -<a > Cove r Plat e Assembly , (£&} Fue l Cap Fille r Nec kHea d Fue l Pum p Pulsator/Dampe r Fue l Leve l Gaug e Sende r Uni t Fue l Filter / Straine r ^t**^ y Fue l Fee dFilte r "0 " Ring s Fue l Pressur e Regulator .

"**= aa$ Limiting^fe v Orific e ^ (0.055" ) & Rollove r Valv e Fue l Pum

p 0 " Rin g Vapo r

Ven t Lin e Sea l Ventpip e Hose / Tub e Assembl y Fillpip e Hose / Tub e Assembl y mm <tX0XlZIX » Fue l Tank Purg e Contro l Diaphragm

Valv e mnni DElastomeric/Plasti c Hos e qj nStee l Tubin g r=(fez lon g Hos e o r Tubin g Vacuu m Hose/Tub e Assembl y Throttl e Body Purg e Hose/Tub e Assembl y Purg e Lin e Restricto r (0.050" ) Purg e Solenoi dValv e Canister , 1.5L , Ope nBottom , Fron t Moun t

# s^kKecfed ' Hi9h 

# " 9h,s 

# " Ouaw e Identica l t o fue l syste m i n 198 6 Oldsmobil e Cutlas s Ciera :

- Multipor

t fue l injectio n

- Fue l tan k

cove rplat e mounte d rollover/ven t valve w/limitin g orific e

- Electri c fue l pum p i n fue l tan k

- Fillpip e an d ventpip e hose/tub e assemblie s

- Purg e contro l diaphrag m valv e

- Purg e solenoi d valve

- Purg e lin e restricto r

- Fron t mounte d 1.5 L ope n botto m caniste r 1 0

2 

## - J

## Cas e 2 Configuratio n - Stoc k Fue l ^Rattpii P Injecte d w/Stee l Fillpip e an d Ventpip e ^ D c 

## " ,c,, e 1 1

Al l Stee l Fillpip e & Ventpip e Hose/Tub e Assemblie s (N o Hos e Sections )

## Cas e 2 Highlight s - Stoc k Fue l ^Raftpii p u 

## Injecte d w/Stee l Fillpip e an d Ventpip e WDCIIIOK ;

Sam e a s Base Cas e - Stoc k Fue l Injecte d except :

- Hos e section s i n fillpip e an d ventpip e delete d

T l h o 0 )

## Cas e 3 Configuratio n - Stoc k Fue l Injecte d w/Enlarge d Fillpip e 

# I I Battell e 1 3

N o Ventpip e Hose/Tub e Assembl y

Enlarge dFillpip e Hose/Tub e Assembl y

r o ^ i

## Cas e 3 Highlight s - Stoc k Fue l ^^R^ttPii P 1 4 

## Injecte d w/Enlarge d Fillpip e %*Bdiieu e

Sam e a s Base Cas e - Stoc k Fue l Injecte d except :

- Fillpip e enlarge d

- Ventpip e delete d

r o

## Cas e 4 Configuratio n -

Stoc k Carburete d &% 

## O Battell e 1 5

Fue l Pum

p & Pressur e Reyuldto r fue l Retur n Restricto r

* I ni n 1 1 m i Orific e (0.0b!>" ) Antisyphonin g How-Tie " Ven t Tub

e fue l Retur n Line ^ m gartaumm* ^^-Fue l N o Rollove r Vdlv e ai

6 Qnmuso P TankPressur e Contro l Diaphragm Valv e Caniste r Hos e Assembl y Purg e Solenoi d Valv e Purg e Lin e Restricto r Purg e Hose/Tub e Assembl y

## Case 4 Highlights - ^R^ttaii o 1 6 

## Stoc k Carburete d wMiieii e

•Sam e a s Base Cas e - Stoc k fue l Injecte d except : Carbureto rreplace s fue l injectio n Antisyphonin g bow-ti e ven t tub e replace s rollover / ven t valve Tan k pressure contro l diaphrag m valve adde d Purg e contro l diaphrag m valve delete d Differen t purg e lin e restricto rused Fue l bow l ven t solenoi d valve adde d Mechanica l fue l pum p replace s electri c fue l pum p Nonpressurize d fue l fee d lin e replace s pressurize d lin e Fue l retur n lin e restricto rreplace s fue l fee d lin e pulsator/dampe r
J °

## Cas e 5 Configuratio n - Stoc k Fue l Injecte d w/Submerge d Fillpipe 

# I I Battell e 1 7

Fue l Tan k (Lowere dFillpip e Extension )

r Ic o

## Cas e 5 Highlights - Stoc k Fue l #fcD»«taii o » Injecte d w/Submerge d Fillpipe ^twnen e

•Sam e a s Base Case - Stoc k fue l injected except :

- Fillpipe extensio n i n fue l tan k submerged

## Cas e 6 Configuratio n - Stoc k

Carburete d w/Rollove r Valve 

# I I Battell e 1 9

Fue l Pum p& Pressur e Regulato r Fue l Retur n Restrictor . Fue l Retur n Lin e _^.fc * Fue l Feed Filte r

Purg e Solenoi d Valv e Purg e Lin e Restricto r Purg e Hose/Tub e Assembl y

c o c o

## Cas e 6 Highlight s - Stoc k ^RattPif p 2 0 

## Carburete d w/Rollove rValve wwiiiai c

Sam e a s Cas e 4 - Stoc k Carburete d except : Rollove rvalve replace s antisyphonin g bow-ti e ven t tub e

c o

## Cas e 7 Configuratio n - Onboard

w/Stee l Fillnec k

Valv e 

# I I Battell e 2 1

Stee l Refuelin g Ven t an d Rollove r Valv e

IIIIIH M nin»»- —Enlarge d ^ \Vapo rVen t Line s A anmn255 > Antispitbac k Valv e

Canister , 4.5 L

## Cas e 7 Highlights - Onboar d ^RattoH ^ 2 2 

## w/Stee l Fillnec k

Valv e wBaneii e Sam e a s Base Cas e - Stoc k Fue l Injecte d except :

- Liqui d sea l used

- Stee l refuelin g ven t an d rollove rvalve adde d

- Enlarge d vapo rven t line s use d

- T-fittin g adde d

- Antispitbac k

valve adde d

- Enlarge d fron t mounte d 4.5 L ope n botto m caniste rreplace s 1.5 L ope n botto m caniste r

T l C O

## Cas e 8 Configuratio n - Onboar d

w/Solenoi d Tan k

Valve * &



## O Battell e 23

Microswitc h <^L*.*<: : 

### *mt>
N o Rollove r Valv e o r Limitin g Orific e tene dand rgedVapo r

Purg e Contro l Diaphragm Valv e (Engin e Compartment )

Caniste r Purg e Lin e / Canister , 4.5L , Rea r Moun t
1 3

## Cas e 8 Highlight s - Onboard

w/Solenoi d Tan k

Valve 

# I I Battell e 2 4 Sam e a s Bas e Cas e - Stoc k Fue l Injecte d except :

- Liqui d sea l used

- Solenoi d activate d tan k mounte d refuelin g vent , rollove ran d overfil l valve wit h limitin g orific e replace s rollover/ven t valve o n cove rplat e

- Nozzl e activate d microswitc h adde d

- Enlarge d rea rmounted 4.5 L caniste rwit h dust ca p replace s 1.5 L fron t mounte d ope n botto m caniste r

- Lon g caniste rpurg e lin e use d

- Enlarge d vapo rven t lin e use d

- Purg e contro l diaphrag m valve remain s i n engin e compartmen t

- Antispitbac k

valv e adde d

- Ventpip e delete d

c o o o

## Cas e 9 Configuratio n - Onboar d

w/Mechanica l Tan k

Valv e 

# I I Battell e 2 5 

# <s » 

# .«- < 

# ^ *^& >

Limitin g Orific e Overfil l & Rollove r Valv e Refuelin g Vent , Overfil l & Rollov e Valv e N o Ventpip e Hose/Tub e Assenib l

\ N o Rollove r Valv e o r Limitin g Or i fic e Shortene d& Enlarged . Vapo r Ven t Lin e

Purg e Contro l Diaphrag m Valv e (Engin e Compartment ) AQmrrrflfi

P (Xt rTn t Caniste r Purg e Lin e Canister , 4.5L , Rea r Moun t

c o C O

## Cas e 9 Highlight s -Onboar d ||Battell e 2 6 

## w/Mechanica l Tan k

Valve Sam e a s Base Cas e - Stoc k Fue l Injecte d except :

- Liqui d sea l use d

- Tan k mounted rollover , refuelin g ven t an d overfil l valve wit h limitin g orific e replace s rollover/ven t valve wit h limitin g orific e o n cove rplate

- Enlarge d rea rmounte d 4.5 L caniste rwit h dust ca p replace s 1.5 L fron t mounte d ope n botto m caniste r

- Lon g caniste rpurg e lin e use d

- Enlarge d vapo rven t lin e used

- Purg e contro l diaphrag m valve remain s i n engin e compartmen t

- Antispitbac k

valve adde d

- Ventpip e delete d

T J

## Cas e 1 0 Configuratio n - Onboar d

w/Plasti c Fillnec k

Valve 

# I I Battell e 2 7

Overfil l Relie f Valv e Mechanica l Sea l

Plasti c Fille r Nec kHea d Refuelin g Ven t & Rollove r Valv e <&

@f > (Adde dHos e Sectio n) Fillpip e Hose / Tub e Assembl y (Adde dHos e Sectio n) Ventpip e Hose / £ , Tub e Assembl y

Canister , 4.0 L
P

### Cas e 1 0 Highlight s - Onboar d ftRaitpil p 2 8 

### w/Plasti c Fillnec k

Valv e WDOIICII C Sam e a s Base Cas e - Stoc k Fue l Injecte d except : Plasti c fillnec k

mounted refuelin g ven t an d rollove r valve adde d Mechanica l sea l adde d Overfil l reliefvalv

e adde d o n fillnec k Additiona l fillpip e an d ventpip e hose section s adde d Enlarge d vapo r ven t line s use d

- T-fittin g adde d Enlarge d fron t mounted 4.0 L ope n botto m caniste r replace s 1.5 L fron t mounte d ope n botto m caniste r

r o4% i



## Componen t Grouping/Hierarch y

## fI Battelle 29

•Components groupe d into 4 subsystem s base d o n functio n an d locatio n Fue l reservoi r Vapo rven t lin e an d caniste r Caniste rvacuum/purg e Fue l suppl y
•Allowe d assessin g probabilit y o ffailure mode s at highe rleve l
•Provide d consistency i n analyse s an d comparison s

C O

## Componen t Groupin g Exampl e 

## O Battelle 30

Subsy s tem/Componen t Fue l Reservoi r Subsyste m

- Refuelin g Nozzle-Fille r Nec k Interfac e

- Fue l Cit[>

- Fue l Tan k Fille r Nec k Hea d Stee l Hea d Plasti c Hea d Leade d Ga s Restricto r Mechanica l Vapo r Sea l Overfil l Relie f Valv e

- Fillpip e Hose/Tub e Assembl y Tub e Hos e Brazed/Welde d Tub e Join t Hos e Connector , Scre wClam p

- Ventpip e Hose/Tub e Assembl y Tub e Hos e , Brazed/Welde d Tub e Join t Hos e Connector , Scre wClam p No . o f

Item s i n Bas e Cas e 1 1 1 1 N A 1 N A N A 1 2 1 2 2 1 2 1 2 2 Cas e

2

1 N A N A 1 N A N A Numbe r o f Item s i n Case s 2-10 * Cas e 3

N Azzzz>>>> Cas e 4 Cas e 5 Cas e 6 Cas e 7 Cas e 8

NAxxxx>>>> Cas e 9

N A N A N A N A N A Cas e 1 0

N A 1 1 1
2 1 4
2 1 4 'N o entr yimplie s sam e a s bas e case .

## 5 ) Analysi s Approac h | | Battell e 3 1

•Establishe d FMECA proces s an d forma t •Define d FMECA categorie s an d develope d rankin g methodolog y an d criteri a (e.g . hazard , hazard probability , leakag e rate , proximit y t o ignitio n source , severity , risk ) •Determine d failur e mode s an d possibl e cause s fo reac h componen t •Determine d effect s an d hazard s fo roperatin g state s an d failur e mod e •Performe d rankin g (scoring ) proces s •Tabulate d risk

s •Compare d b

y cas e an d operatin g state

c n

## FMEC A Proces s .m. 

# O Battell e 32

Efte d (tos s o fsea l Integrity) 

# J 

# f

FaiKir a Mod * (broken ) 

# ] 

# f
Possfcfe Caus a (imprope rinstallation ) 

# 3 t Componan t (hos a clamp ) 

# J Hazar d (leakag e o l fua l orvapor ) )

Severity (leakag e rata , proximit y t o ignitio n source ) 

# J Hazar d Probability (likelihoo d tha t failur e mod e occurs an d result s i n hazard ) )P.4 7

0 )

* = 

### cu C Q IMF

0 5 

## £ o L L < 

## O LU .at fl. 1 * " 8 a 1 v

r~-

mO t / 1

K O k - &
-a £ 4 > 0 ) < c

- J ( X j a mC. N o
^ "

r^ j

* ~ = o .

At-. uEffe

0 ) mm. C L « Q o * - l/ lossibleCauses

a . ^ . tA 0 )FailureMo 1 I |
I i l i i i i i i I i i i 

## I i i i i [ i i i i ! i i

## Failure Modes/Possibl e Cause s .*%. 

## pBaffell e 3 4 Failur e mode s consistentl y assigne d base d o n componen t typ e Possibl e cause s identifie d fo reac h failur e mod e Failur e o fmountin g hardware include d a s possibl e cause s Cause s originat e i n al l phase s o fvehicl e life (design , manufacturin g an d use)

0 0

## Operatin g State s an d

Characteristic s .M. 

## %I Battell e 3

5


# L Stat e

Refuelin g (R ) Drivin g (D ) Parke d (P ) Car

Movemen t N o Ye s N o Engin e

Of f O n Of f Sever e Traffi c Accident s N o Ye s Ye s Rollove r

N o Ye s N o Fue l

Ca p Of f O n O n

## Effect

s Q Battell e 36
Effect s cite d fo reac h failure mod e o feac h componen t fo reac h operatin g state Effects ar e worst cas e Effects cite d ar e presen t durin g specifi c stat e

c n o

## Hazard s * * 

## O Battell e 3 7 Category Descriptio n V L N Leakag e offue l vapo ronl y

Leakag e ofliqui d fue l (subsequentl y form s fue l vapor ) Essentiall y n o leakag e

X I c n

## Hazar d Probability 

# I I Battell e 3 8

•Definitio n - Likelihoo d that failure mod e exists i n operatin g stat e wit h particula reffect s an d hazard s
•Base d on : Fue l syste m desig n difference s

Expecte d relative occurrence s o ffailure modes Vulnerability an d orientatio n o fcomponents Professiona l an d persona l experienc e
•Augmente d whereve rpossibl e b y dat a foun d i n literature

c n r o

## Hazard Probabilit y Scal e •3>-i- 

## O Battell e 3 9 

### Descriptio n Ran k Relativ e Probabilit

y Fo rIndividua l Vehicl e Frequen t Probabl e Occasiona l Remot e Improbabl e A Likel y t o occu rfrequentl y

i n life o fvehicl e B Wil l occu rsevera l time s i n life o fvehicl e C Likel y t o occu rsometim e i n life o fvehicl e D Unlikel y bu t possibl e t o occu ri n life o

fvehicl e E S o unlikely , i t ca n b e assumed occurrenc e ma y no t b e experience d i n lif e o fvehicl e

c n c o

## Leakag e Rate Scal e 4 % 

## C l Battell e 4 0



### Rankin g Leakag e Rate Criteri a I I I II I I V >11 0 g/ 5 mi n

11-11 0 g/ 5 mi n 1.1-1 1 g/ 5 mi n <1. 1 g/ 5 mi n >NHTS A limit 1 

### >1/1 0 NHTSA limi t <1/1 0 NHTSA limi t Zer o o rnearl y s o

* Base d o n NHTS A specificatio n of5 oz/ 5 mi n fo rFMVS S 30 1 cras h testin g

O l

## Potentia l Ignitio n Source s 4 * 

## OTatteiie 4 1 Sparks/Arc s

- Electrica l components/wirin g an d frictio n Hot Surface s

- Hot engin e

- Exhaus

t component s

- Meta l heate d b

y electrica l shorts

- Hot particle s produce d b y frictio n Flame s Intak

e o rexhaust backfire s

c n c n

## Proximit

y T o Ignitio n Source Scal e 4 % 

## C I Battelle 4 2
Rank* I I I II I Criteri a O n o rimmediatel yadjacen t t o engin e

» Othe rlocation s i n engin e compartmen t Everywher e els e o n vehicl e
*Base d o n likelihoo d tha t ignitio n sourc e exist s i n clos e proximit yt o lea k

c n 0 )

## Severit

y 4* . 

## O Battell e 4 3 

### Proximit y t o Ignitio n Sourc e O n Nea r Leakag e Rate (g/ 5 min ) >11 0 11-11 0 <1 1 Zer o Descriptio n Ran k Hig h 1 Mediu m 2 Lo w3 Negligibl e (n o hazard ) 4
* Massiv e liqui d fue l leak

s considere d Ran k

1 

### Fa r 1 1 2 4 1

2 2 4 2 *

2 3 4

• A,'»*-l-** ' ? 0

# Ris k

I I Battell e 4 4



### •Definitio n - Likelihoo d offir e du e t o a liqui d fue l o rvapo rlea k •Functio n o

fprobability an d severity •Examples : Hazar d Probability Severity Ris k C 2 2 C D 1 1 D •Highest ris k

i s 1A , lowest i s 3 E

cn o o

# 6 ) Result

s I I Battell e 4 5



### FMEC A table s Ris k matrice s Ris k leve l comparison s Summar y

c n c o

## FMEC A Tabl e Exampl e .i?* . 

# O Battell e 46

Component : Ventpipe Hose/Tube Assembl y

Failur e Modes/Possibl e Cause s Smal l hole , crack or sea l failure

- Manufacturin

g error (brazing , welding )

- Clam pomitted , wron

g type , not full

y tightened , loosens , o r fail s

- Wron g hos e materia l and/or siz e

- Hos e aging/crackin g

- Hos e abrasio

nfro m adjacent par t

- Struck b

y objec t (e.g. , stone , accident )

- Excessiv

e interna l pressur e

- Tube corrosio

no r joint failure

- Suppor t bracke t o r fittin g failure Ruptured/cut/severed/disconnected

- No t connectedor misrouteddurin g manufactur e o r repai r (e.g. , stone , accident )

- Excessiv

e interna l pressur e

- Suppor t bracke t or fittin g failure Obstructe

d

- Kinke ddurin g manufactur e or repai r

- Blocke

db y foreig nmateria l

- Swellin

g (wron g material )

- Kinke do r pinche

ddurin g vehicl e accident

- Collapsedfro

m excessiv

e vaccu m O

p Stat e R D P

R D P R D 1 ' Effec t Los s o f ventpipe integrity Vapor/fue l splashou t an dflui dlos s with rollove r Los s o f ventpipe integrity
Loss , of ventpip

e integrity Vapor/fue l splas hout an dflui dlos s with rollove r Los s o f ventpip

e integrity Fue l spitback Tan k vente dvi a fillpipe * Ha z V, L V, L V

V, L V, L V L N N Ha z Pro b D 0 0

D D D D

-

- Leak Rat e I I I I II I

I I II I II I I V I V Pro

x II I II I II I

II I II I II I II I

-

- Se v 2 2 3

2 1 3 3 4 4 Ris k 2 D 2 D 3 0

2 0 1 0 3 0 3 D

-

-

T J 0 0

## Ris k

Matri xExampl e m. 

# O Battell e 4 7 

### Risk s tallie d b

y countin g FMEC

A entrie s fo reac h cas e an d operatin g state :
A B Hazar d C Probabilit

y D E Total s 

### Severit

y 1 2 3 0 0 0 1 6 7 2 3 3

2 2 3 3 7 9 11 9 0

0 1 9 2 5 3 5 Gran d Tota l 

### 17 7

M/I.--M- 1 \

## Ris k

Leve l Index •fif e 

# O Battell e 48 

### Matri xentrie s groupe d b y combinin g simila rrisks :
Hazar d Probability A

B C D E RiS r 1 I

II I 

### Severit

y 2 3 

# l l I I II I II I IV 

### 4
v

c Leve l Relativ

e Ris k i 

### I I 

### i n I V V Hig h

Mediu m Lo w Ver y Lo w Non e

*A/l»y.|.4«- 1 -4 A
O ) r o

## Ris k

Leve l Compariso n Char t Al l States 

# p Battell e 4 9

16 0 Ris k Leve l an d Cas e

LU 0 ) • M B D C 0 ) E 3 15 0 - 14 0 - 1 JO 12 0 1 1 0 - 10 0 - 9 0 - a o - 7 0 - 6 0 5 0 - 4 0 - 3 0 - 2 0 - 1 0 - 0 ZHZEC p /\?$x/ \ /\^$x/\^Jx l /s^sx/\^ x /f^M/
A4AI /\^x/\^ x A<K /\£$x/\£$ x

/\£$x/\*s x /\^$x/\*$ x /\/;s:x/\^$ x /\£$x/\£$ x /\«x/\^$ x /\2$x/\£$ x /\Z$r<r'\Z§X /\2NX/\^S: X /\£$x/x*$ x /\^$x/\^ x /\2Sx/x^ x

f7P3 / X / x / X 2- S

Leve l I Leve l I I Leve l II I Leve l I V Note : Case s 1-1 0 show n lef t t o righ t

## Ris k

Leve l Compariso n Al l State s •&% 

# O Battell e 5 0 Findin g Ris k entrie s increas e a s ris k leve l decrease s Case s 8 , 9 an d 1 0 lowest i n ris k leve l I Case s 7 , 8 an d 9 lowest i n ris k leve l I I Case s 8 an d 9 lowest i n ris k leve l II I Case s 4 , 6 , 8 an d 9 highest i n ris k leve l I V Drivin g Facto r Most risk

s no t o fsever e nature (ris k

shift) Refuelin g emissio n contro l an d rea rmounte d caniste r (case s 8 an d 9 ) Antispitbac k

valve Rea rmounte d caniste r Case s 8 an d 9 lowe ri n mor e critica l ris k

levels ; more complexcaniste rvacuu m an d purg e configuration s i n case s 4 an d 6

## Ris k

Leve l Compariso n Char t - Refuelin g Stat e 

# OBafleii e 5 1
Ris k Leve l an d Cas e 6 0
5 0
4 0
3 0 - 2 0
1 0 - CO C U J G C « * - O i _ < D 

### n E 3 PT^^Y 1 ^^ 1 

### nwffi ^ 2 K -< i N n 7 X >

7 sr^SX/N ^ ^ \^X/\£$ X s^X/\^ X

iti : / ^^ 3 /f^^x/\^ x /\^$x/\^s x /\^sx/\^$ x /\/;sx/\$$ x /\£$x/\^$ x /\$$x/\^$ x /\^$x/\^$ x /\£$x/\^$ x /\^$x/\^$ x /\«x/\^s x /\^x/\$$ x /\£s:x/\£s> < /\^x/\^ x d S

Leve l I Leve l I I Leve l II I Leve l I V Note : Case s 1-1 0 show n lef t t o righ t

## Ris k

Leve l Compariso n Refuelin g Stat e 

# I I Battell e 5 2 Findin g Case s 8, 9 an d 1 0 lowest i n ris k leve l I Case s 7 , 8 an d 9 lowest i n ris k leve l I I Case s 3 an d 9 lowest i n ris k levelll l Cas e 1 0 highest i n ris k leve l • II I Case s 4 , 6, 8 an d 9 highest i n ris k leve l I V Drivin g Facto r Refuelin g emissio n contro l an d rea r mounte d caniste r(case s 8 an d 9 ) Antispitbac k

valve inhibit s liqui d fue l spitbac k Rea rmounte d caniste ran d anti spitbac k valve i n cas e 9 ; lac k

o f ventpip e i n cas e 3 More connection s i n fillpipe / ventpipe , an d fillernec k hea d complexit

y Case s 8 an d 9 lowe ri n more criti ca l ris k levels ; mor

e complex caniste rvacuu m an d purg e configuration s i n case s 4 an d 6

## Ris k

Leve l Compariso n Char t Drivin g Stat e 4 % 

# O Battell e 5 3

C O C D c L U C O
• 1M B G C C D J Q E 3 6 0
5 0 - 4 0 - 3 0 - 2 0 - Ris k Leve l an d Cas e

/\«x/\^ x /\vsx/\xS x 1 Leve l I /\: 

### iA

/K - 1Y YCAx Bx/\^ x / \ A<K ^ b P S \

s^X/N^ X v^X/N^ X >sx/\^s x

<S X 

# I

KM & /\£$x/\£$ x /\x$x/x£s: x /\^x/\$$ x /\x$x/x^s: x /\2$x/\^$ x /\x$x/\^$ x /\£$x/\^$ x /\^$x/\^$ x /sv.sx/sv.sx /\\V.%X/\A%X Z$x/\t$x

RIS 3 £x 

### ''A

^t : Leve l I I Leve l II I Leve l IV Note : Case s 1-1 0 show n lef t t o righ t

## Ris k

Leve l Compariso n Drivin g Stat e 4 % 

## O Battelle 5 4 Findin g N o risks i n ris k

leve l I Case s 3 , 4 , 6 , 7 an d 9 lowest i n ris k

leve l I I Case s 8 an d 9 lowes

t i n ris k levelll l Case s 4 , 6 , 8 an d 9 highest i n ris k leve l I V Drivin g Facto r Fue l ca p i n plac e an d caniste r purgin g Lac k o fventpip e i n case s 3 an d 9 ; lo wpressure fue l line s i n case s 4 an d 6 ; antispitbac k

valve i n case s 7 an d 9 Rea rmounte d caniste r Case s 8 an d 9 lowe ri n more criti ca l ris k levels ; more complex caniste rvacuu m an d purg e config uration s i n case s 4 an d 6

## Ris k

Leve l Compariso n Char t - Parke d State &*a 

## % 9 Battell e « Ris k Leve l an d Cas e
C O C D c L U C O C D 

### n E 3 

### z 6 0

5 0
4 0
3 0
2 0 - 1 0 -

• • T^ Ty , i r^ PN^XpU^X ] /\-x$x/\^ x /\^x/\^ x /\^x/\^ x /\^x/\^ x /\XSX/\XS X /\xsx/\xs x /sxsx/sxs x /\xsx/\xs x /\xsx/\xs x /\XSX/\XS X /\XSX/\XS X /\XSX/\XS X /\XSX/\XS X /\XSX/\XS X /\xsx/\xs x /\XSX/\XS X Leve l I Leve l I I Leve l II I Leve l I V Note : Case s 1-1 0 show n lef t t o righ t

## Ris k

Leve l Compariso n Parke d Stat e 

# I I Battell e 5 6 Findin g Case s 8 an d 9 absen t o f risk s i n ris k leve l I Case s 4 an d 6 highest i n ris k leve l I I Case s 8 an d 9 lowest i n ris k leve l II I Case s 4 , 6 , 8 an d 9 highest i n ris k leve l I V Hig h numbe ro

frisk s i n ris k leve l I V Drivin g Facto r Rea rmounte d caniste r Fue l bow l ven t solenoi d valve Rea rmounte d caniste ran d relocatio n o

fvapo rven t lin e Case s 8 an d 9 lowe ri n more criti ca l ris k levels ; more complex caniste rvacuu m an d purg e config uration s i n case s 4 an d 6 Parke d state i s lo

wi n critica l risk s

X I ^ 1 o

## Summar

y o fResults 

# I I Battell e 5 7 

### Highe r Bas e Cas e ••a • 

### Lowe r 

### 2,3,4,5,6, 0 " 2,3,4,5,6,111 0 

# m 

# im m IZ.1 0 •-2,4,5, 6 ••• • 3 

# i i 4 H

6 

# 0 •—2,3,5jl0 —
Ris k Leve l I Ris k

Leve l I I Ris k

Leve l II I Ris k

Leve l I V Q = Onboard system s

r> i^Dott^ll ^ 5 8 

## 7 ) Conclusion s ^Battell e 1 ) Most risk

s fo ral l case s an d state s hav e "remote " o r "improbable " likelihoo d o foccurrenc e 2 ) Most risk

s fo ral l case s an d state s hav e mediu m severity o rles s 3 ) I n general , leve l o

fris k i s no t greatl y differen t amon g case s 4 ) Of1 0 case s analyzed , onboar d system s hav e relativel y les s overal l ris k tha n stoc k

system s

r o